Lecture 2: Oxy-Coal Combustion TechnologyA Competing Option for Coal Fired Power Plants with CO2 Capture

Stanley SantosIEA Greenhouse Gas R&D Programme

2nd APP Oxyfuel Working Group Capacity Building CourseBeijing, China

15th March 2010

Overview• Introduction – Oxyfuel Combustion• Overview to the Current Status of Large Scale Oxyfu el

Combustion Demo Projects • Vattenfall Project• CS Energy Project• CIUDEN Project

2

• CIUDEN Project• Large Scale Burner test facilities worldwide

• Overview to the Key Challenges in the Development o f this Technology• Boiler and Burner Development• Oxygen Supply• CO2 Processing

• Concluding Remarks

IntroductionOxyfuel Combustion for Coal Fired Power Plant with CO2 Capture

3

Introduction• Oxyfuel Combustion Technology

• This is not a new technology. This has been developed for several decades for various industrial applications.

• Development of oxyfuel combustion for boiler

4

• Development of oxyfuel combustion for boiler application started in 1970’s.

• First oxy-coal combustion pilot test was done by ANL during the 1980’s

• First large scale oxy-coal burner test was done by International Combustion in 1990’s

Development of Oxy-Fuel Combustion Application in Industry

5

Adapted from slide of Sho Kobayashi, Praxair

Pictures from IFRF, Air Liqiude, Asahi Glass, Linde Gas

ANL - EERC StudyWorld’s 1st Oxy-Coal Combustion Industrial Pilot Sc ale StudyTower Furnace (~ 3MWth)

6

Current Status:Oxy-Fuel Combustion Boiler Projects

7

Large Scale Pilot and Demo ProjectsUpdated by S. Santos (06/09/09)

PROJECT Location MW th Start Up Year Boiler Type Main Fuel CO 2 Train

B & W USA 30 2007 Pilot PC Bit, Sub B., Lig.

Jupiter USA 20 2007 Industr. No FGR NG, Coal

Oxy-coal UK UK 40 2009 Pilot PC Bituminous

Alstom (Windsor Facility) USA 15 2009 Pilot PC (Tangential) Bit., Sub B., PRB

Vattenfall Germany 30 2008 Pilot PC Lignite (Bit.) With CCS

Total, Lacq France 30 2009 Industrial boiler NG With CCS

Callide Australia 90 2010 30 MWe PC Bituminous With CCS

CIUDEN – PC Spain 20 2010 Pilot PC Anthra. Bit, Lig. Coke With CCS

CIUDEN – CFB Spain 30 2010 Pilot CFB Anthra. Bit, Lig. Coke With CCS

ENEL HP Oxy Italy 48 2012 Pilot Plant Coal

HBPW – Michigan / Praxair USA 225 2014? ~75 MWe CFB Bit. With CCS

Vattenfall (Janschwalde) Germany ~1000 2014? ~300 MWe PC Lignite (Bit.) With CCS

Endesa/CIUDEN Spain ~1000 2015? ~300 MWe CFB? ? With CCS

Black Hills Power/B&W/AL USA ~400 2015? ~100 MWe PC With CCS

KOSEP/KEPRI Yongdong Korea ~400 2018? ~100 MWe PC ? ?

Vattenfall’s Schwarze Pumpe Pilot Plant• The World’s 1 st Pilot Plant – that

demonstration a full chain oxyfuel process producing steam.

• As of January 2010 – they have achieved nearly 4500 operating hours.

9

nearly 4500 operating hours.

• A unique testing bed for burner / boiler evaluation.• down fire system

• Consists of 3 burner testing periods.• 2 burner testing period to be undertaken using

different Alstom’s burner for lignite and hard coal• 1 burner testing period to be undertaken using

Babcock Hitachi’s burner for lignite Courtesy of Vattenfall, Alstom

Vattenfall’sVattenfall’s Effort in Leading Effort in Leading OxyfuelOxyfuel DevelopmentDevelopment

2009 2010 20112005 2006 2007 2008

Pre- and Order planning

Permission planning

Execution planning

Time Table for Implementation of Oxy-Fuel Project

www.ieagreen.org.uk

Commissioning

Erection

Operation

Courtesy of Vattenfall

Jänschwalde demonstration plant – view from south east

PCC

Cooling waterpump

CO2-compression

NH3-storage

© Vattenfall AB 12

Fuel feeding

Lignitedryer

Oxyfuelboiler

ASU

Flue gas cleaning

CO2-compressionPreparation and cleaning ofLignite condensate

PCC

CO2-transport

CO2-compression

Jänschwalde demonstration plant. 500 MW with oxyfuel and post combustion capture

© Vattenfall AB 13

CS Energy/IHI Burner Testing Programme at Callide A Power Station

• Callide A Project – would be the world’s 1 st oxyfuel retrofitted power station.• First oxyfuel pilot plant that will actually

produce electricity.• Installation of 2x ~45MWth Wall Fired

Burners

14

Burners• A unique position to provide information

related to the burner – burner interaction • Project Scope (4 years operation):

o Oxygen plant (nominal 2 x 330 tpd ASUs)o Boiler refurbishment and oxy-fuel retrofit (1 x 30

MWe Unit)o CO2 compression & purification (75 tpd process

plant from a 20% side stream)o Road transport and geological storage (~ 30 tpd

liquid CO2)14

Courtesy of CS Energy, IHI

COP Design Studies – Oxyfuel boiler modifications

Coal HRA

Stack

図図図図ASU & CO2

compression area

No.4 No.4 No.4 No.4 UnitUnitUnitUnit Side elevation Side elevation Side elevation Side elevation

planplanplanplan

Main modification parts

Coal HRA

Stack

図図図図ASU & CO2

compression area

No.4 No.4 No.4 No.4 UnitUnitUnitUnit Side elevation Side elevation Side elevation Side elevation

planplanplanplan

Main modification parts

Coal bunker

Mill/PAF

Boiler

HRA

Fabric filter

Feed water heater Burner

Water scrubber

Plot Plot Plot Plot planplanplanplan

Coal bunker

Mill/PAF

Boiler

HRA

Fabric filter

Feed water heater Burner

Water scrubber

Plot Plot Plot Plot planplanplanplan

CIUDEN CO2 Capture Programme.

• First oxyfuel pilot plant that will demonstrate in large scale the Oxy-CFB technology.

• Oxy-PC facility is very complimentary to Vattenfall’s and Callide’s facilities.

16

• Could be in a unique position to provide information related to the burner – burner interaction (in smaller scale).

• 1st facility to investigate Anthracite (this would be first in the world), Petcoke and Biomass.

PC BoilerSize (m) 24 x 7,6 x 4,5

Burners4 horizontal burners

2 vertical burners

MWt PCS maxoxycombustion

mode20

O2 (kg/h) 6600

Recirculation

CIUDEN: CO2 Capture TDP main characteristics

Recirculation gas flow (kg/h) 17900

Flue gas flow (kg/h) 26400

Coal flow rate (kg/h) 3350

Steam (t/h) 25

P(bar) / T ( °C) 30 / 420

CFB Boiler Dimensions (m) 21x2,7x2,4

MWt SCP maxoxy-combustion 30

O2 (kg/h) 8775

Flue gas recycle(kg/h) 25532

Flue gas (kg/h) 28800

CIUDEN: CO2 Capture TDP main characteristics

Coal feed (kg/h) 5469

Limestone feed (kg/h) 720

Steam (t/h) 44,6

P(bar) / T ( °C) 30 / 250

Today... There are 3 Major Full Scale PC Burner Testing Facilities Worldwide Retrofitted for Oxyfuel

19

• Babcock and Wilcox (B&W)30MWth CEDF

• Barberton, Ohio, USA• Start of Operation: Oct. 2008• Wall Fired Burner

Development

19

• Doosan Babcock –40MWth in 90MWth MBTF

• Renfrew, Scotland, UK

• Start of Operation: Jun. 2009

• Wall Fired Burner Development

• Alstom Power Plant Lab. –15MWth in 30MWth BSF

• Windsor, Connecticut, USA

• Start of Operation: Nov. 2009

• T-Fired Burner Development

Courtesy of Alstom, B&W and Doosan Babcock

Burner Development for Oxyfuel Combustion

• Burners are critical to combustion, emissions, and thermal efficiency / capacity of the utility boilers

• Critical importance to burner development is a

20

• Critical importance to burner development is a full scale testing• This is an important exercise to establish reference data

that could be used in the development and validation of different modeling tools.

• This is also to gain experience in operating full scale burner. (i.e. start up/shut down, flame stability, efficiency, heat transfer, fouling and slagging, etc…).

20

Burner Development for Oxyfuel Combustion

• Development of Full Scale Burner Testing Programme could either be accomplished by:

• Retrofitting of Full Scale Burner Test Rigso B&W’s 30MWth CEDF Facility (Ohio, USA) o Doosan Babcock’s 40MW MBTF Facility (Renfrew, Scotland)

21

o Doosan Babcock’s 40MWth MBTF Facility (Renfrew, Scotland)o Alstom ‘s 15MWth BSF Facility (Connecticut, USA)

• Testing in a Full Chain Oxyfuel CCS Pilot / Demo Planto Vattenfall’s Schwarze Pumpe Pilot Plant (Cottbus, Germany)o CS Energy’s Callide Power Plant (Queensland, Australia)o TOTAL’s Lacq Facility (Lacq, France)o CIUDEN Demo Facility (El Bierzo, Spain)

Challenges to Boiler and Burner Development• Recycling of the Flue Gas

• What are parameters that we should consider in the burner design? (Flame stability, Heat Transfer, Carbon in Ash, Pollutant Formation - especially CO, O2 injection point, etc...)

22

point, etc...)

• Air ingress issue• What is the maximum allowed that would not affect the

design of the CO2 processing unit?

• Other Combustion Issues• Corrosion• Slagging and Fouling• Emissions

Normalised Convective & Radiativeheat flux – Russian Coal - Dry Recycle

Dry Oxyfuel Operation Normalised to Air OperationPeak Radiation Flux, Convective heat transfer and c alculated flame temperature

Russian coal

1.2

1.4

1.6

Nor

mal

ised

Adi

abat

ic

Fla

me

Tem

pera

ture 1.2

1.4

1.6

Nor

mal

ised

Rad

iativ

e an

d C

onve

ctiv

e H

eat F

lux

Normalised Flame Temperature (calculated)

Peak Normalised Heat Flux (measured)

Normalised Convective HTC (measured)

Measured Convective Heat Transfer Coefficient indicates 74% Recycle is "Air-equivalent"

Measured Peak Radiative data indicates 74%

New Build Retrofit Avoid

23

0.4

0.6

0.8

1

1.2

60% 65% 70% 75% 80%Effective Recycle Ratio

Nor

mal

ised

Adi

abat

ic

Fla

me

Tem

pera

ture

0.4

0.6

0.8

1

1.2

Nor

mal

ised

Rad

iativ

e an

d C

onve

ctiv

e H

eat F

lux

Calculated dry oxyfuel adiabatic flame temperatures are equivalent to air at 69% recycle

data indicates 74% Recycle is "Air-equivalent"

Problem with Air Ingress1st Large Scale Oxy-Coal Combustion Burner Test Experience - International Combustion Lt d.

24

� 30 MWth Low NOx burner

� Because of Air Ingress the desired CO2composition (only ~ 28% dry basis).

� Air Ingress in boilers

� approx. 3 % of flue gas flow fora new conventional power plant

� up to 10 % over the years forpower plants in use

CO2 Recovery Depends On Feed Composition

Recovery

0.4

0.6

0.8

1

25

At -55°C, 30 barFeed Composition

0

0.2

0.4

0 0.2 0.4 0.6 0.8

SO3 Emissions(Results from ANL-EERC, IVD Stuttgart, Callide/IHI)

10

12

14

16

18

20

Con

cent

ratio

n (p

pm)

ANL - Air ANL - Oxy

IVD Stuttgart - Air IVD Stuttgart - Oxy

Callide IHI - Coal A - Air Callide IHI - Coal A - Oxy

Callide IHI - Coal B - Air Callide IHI - Coal B - Oxy

26

0

2

4

6

8

10

0 250 500 750 1000 1250 1500 1750 2000 2250

SO

3 C

once

ntra

tion

(ppm

)

SO2 Concentration (ppm)

Challenges to Oxygen Production• As of today, the only available technology for

oxygen production in large quantities is cryogenic air separation .

• Advances and Development in ASU could result to 25% less energy consumption.

27

result to 25% less energy consumption.• These design would be based on either a

3 column design or dual reboiler design.

• Challenges are:• Cost of production of oxygen (energy

consumption)• Utilisation of nitrogen within power plant.

ASU Distillation Process

N2

LPCOLUMN

N2

10 - 12%

Less kW

Double Column Cycle Side Column Cycle

28

HPCOLUMN

Air

O2

HPCOLUMN

Air

O2

Less kW

Liquid Vapor Equilibria Figure from F. Kerry (2007)

Challenges to CO2 Processing Unit• The CO2 processing unit could be very

competitive business (an important growth area) for industrial gas companies.

• Challenges are:

29

• Challenges are:• Demand of the quality requirements of the CO2 from the

power plant for transport and storage. What are the Required Specification?

• Further recovery of CO2 from the vent will make oxyfuel more competitive if high recovery of CO2 is required!

• Need a large scale demonstration of the CO 2processing unit using impure CO 2 as refrigerant.

76%mol CO224% inerts (~ 5 - 6% O2)

96%mol CO24% inerts (~ 0.95% O2)

25%mol CO275% inerts (~ 15% O2)

72%mol CO228% inerts(~ 5 - 6% O2)

98%mol CO22% inerts(~ 0.6% O2)

25%mol CO275% inerts(~ 19% O2)

25%mol CO2

30

72%mol CO228% inerts(~ 5 - 6% O2)

99.999%mol CO20.001% inerts(~ .0005% O2)

25%mol CO275% inerts (~ 15% O2)

72%mol CO228% inerts(~ 5 - 6% O2)

99.95%mol CO20.05% inerts(~ .01% O2)

25%mol CO275% inerts(~ 15% O2)

Use of Membrane to recover CO2 and O2 at the vent

Vent:7% CO293% inerts (~10% O2)

Product

31

Product96% CO24% inerts (~0.75% O2)

Concluding Remarks• Oxyfuel Combustion Technology is a viable option

for any coal fired power plant with CO2 Capture.• Oxyfuel Combustion Technology is an option for

new build or retrofit cases.• We need to demonstrate Oxyfuel Combustion

32

• We need to demonstrate Oxyfuel Combustion Technology to build our confidence.

• Business sense, it could have a simple business model for power generation companies wherein the operation of the ASU and CO2 processing could be outsourced with a long term supply contract from the industrial gas companies.

Alstom Schwarze Pumpe 2008 30MWth Lignite

Hitachi Babcock Schwarze Pumpe 2010 30MWth Lignite

IHI Callide 2011 30MWe

Alstom / AL Lacq 2009 30MWth Gas/Oil?

CIUDEN El Bierzo CFB Facility 2011 30MWth Coal

El Bierzo PC Facility 2011 20MWth Coal

Coal

CIUDEN

Brindisi Test Facility 2012 48MWth CoalENEL HP Oxyfuel

2008

World’s FIRST 30 MWt

full chain demonstration

at Schwarze Pumpe Pilot Plant

2009 – Lacq – World’s

first 30MWt

retrofitted Oxy-NG

boiler2011 – CIUDEN –

World’s first 30MWt

Oxy-CFB Pilot Plant

2011 – Callide –

World’s first 30MWe

retrofitted Oxy-coal

power plant

By 2014-2018

Demonstration of

50– 300MWe full

scale power plant.

Target :

“Commercialised by 2020”

Vattenfall - Janschwalde (PC -250MWe)

KEPCO/KOSEP - Yongdong (PC - 100MWe)

Black Hills Power - Wyoming (PC - 100MWe)

FW/Praxair – HBPW Michigan (CFB - 78MWe)

Endesa/CIUDEN - El Bierzo (CFB - 300MWe)

1980’s

ANL/Battelle/EERC completed the first

industrial scale pilot plant

1990 - 1995

EC Joule Thermie Project

- IFRF / Doosan Babcock / Int’l Combustion

NEDO / IHI / Jcoal Project

First large scale 35MWt

Oxy-Coal Burner Retrofit

Test done by

International Combustion

1998 – 2001

CANMET

US DOE Project / B&W / Air Liquide

2003 - 2005

Vattenfall (ENCAP ++)

CS Energy / IHI Callide Project

B&W CEDF 2008 30MWth Coal

Alstom Alstom CE 2010 15MWth Coal

Doosan Babcock DBEL - MBTF 2009 40MWth Coal

2007

B&W CEDF (30MWt)

large scale burner testing started

Updated by S. Santos (05/09/09)

at Schwarze Pumpe Pilot Plant

By the end of 2010/2011,

Users (i.e. Power Plant Operators)

will have 6 burner manufacturers

fully demonstrating “Utility Size

Large Scale Burners” which should

give a high level of confidence

toward demonstration

Concluding Remarks

• China could be in a unique position to demonstrate the three leading technology for CO 2 capture.• GreenGen provided the platform to demonstrate

34

• GreenGen provided the platform to demonstrate pre-combustion capture.

• Post-Combustion capture is now being demonstrated in China in slip stream scale.

• Oxyfuel Combustion technology is the only missing link.

Thank you

Email: stanley.santos@ieaghg.orgWebsite: http://www.ieaghg.org